Panel assembly

ABSTRACT

An assembly for use in a door panel or the like comprises a pair of spaced substantially parallel rigid longitudinal channels which include tracks for receiving a substantially planar sheet of cover material and crossmembers are arranged to contact the inner face of the sheet material, the channels and braces being attached to the inner face by an adhesive. The longitudinal channel and crossmembers may be adjustable to provide a variable dimension assembly. The crossmembers include an elongated tongue which is arranged to extend into an elongated slot formed in the longitudinal channels to position the channels in a selected spaced relationship from each other and rigidify the structure.

United States Patent Raymond 11. Aubrey Rte. 2, Box 95-B, Ocala, Fla. 32670 [21] Appl. No. 758,763

[22] Filed Sept. 10,1968

[45] Patented Jan. 5, 1971 [72] Inventor [541 PANEL ASSEMBLY 10 Claims, 7 Drawing Figs.

[52] U.S. Cl. 160/130 [51 Int. Cl. E06b 03/72, E06b 03/76 [50] Field of Search 160/ l 30,

[56'] References Cited UNITED STATES PATENTS 2,557,753 6/1951 Mitchell 160/229 2,784,445 3/ 1957 Greig et al. 49/410 2,863,503 12/1958 Stroup 160/201 2,898,987 8/1959 Ford 160/206 3,019,836 2/1962 Leigh 160/199 3,261,129 7/1966 Brydolfet a1... 49/411 3,319,801 5/1967 Nordstrom 160/135 Primary Examiner-Peter M. Caun Attorney-Molinare, Allegretti, Newitt 8L Witcoff 'hesive. The longitudinal channel and crossmembers may be adjustable to provide a variable dimension assembly. The crossmembers include an elongated tongue which is arranged to extend into an elongated slot formed in the longitudinal channels to position the channels in a selected spaced relationship from each other and rigidify the structure.

PATENTEU JAN 5197! I 5 2 sum 1 or 3 i PANEL ASSEMBLY BACKGROUND or THEINVENTION The invention relates to a panel assembly and, more particularly, a panel assembly for use in door panels and the like.

In the known door constructions, and particularly folding door constructions, an aesthetically pleasing sheet of cover material is generally provided overlyinga relatively rigid frame assembly. Due toconstructionlimitations of such prior doors, the doors must be both manufactured and assembled at the same geographic site, since various jigs, forms and special tools are required in the course of manufacture and assembly. For example, folding doors in the past have been generally formedfrom a sheet metal cover material, the sheet metal I being selectively bent about its periphery to provide the vertical portions of the frame and the crossincmbers being welded between the vertical portions to provide the rigid frame structure. Obviously such construction is not generally possible by the user and consequentlysuch doors have to be substantially assembled in theirfinal'form prior to shipment to' the user.

Shipment of the completed door substantially increases shipping expenses and such doors are not readily adaptable to be customized in either appearance or size to meet unusual desires and needs of the user. Moreover,jthe manufacturing cost of such doors is frequently increased due to the inaccessibility of various materials employed in certain of the door components in the particular geographic area of manufacture. Such is particularly'true of the wide spectrum of cover sheet materials which may be utilized by the assembly of my'invention. Where the prior doors are constructed by attaching one ormore sheets of cover material to a preconstructed frame, such doors were generally susceptible to deterioration during use due to" the loss of screws or deterioration of the adhesive by which the cover material is attached to its frame, the screws and/or adhesive being the only manner of fastening the cover material to the frame. Moreover, such doors are susceptible to shipped in unassembled form to a geographic area having a ready access to desirable sheet cover materials and then assembled in thelatter area. The panel assembly of my invention also obviates the need for complex positioning jigs or forms or sophisticated assembly tools to completefinal assembly and thecomponent parts of my assembly are capable of inexpensive manufacture. Moreover, such assembly in its assembled form is sturdy and may be readily adapted'to be customized with respect to dimensions at the location at which it is to be I used. Finally, my invention minimizes the number of rivets or screws necessary to assemble infmal form the panel assembly while providing a construction which is substantially less susceptible to loosening during use and which rigidly maintains the sheet cover material secure againstwarping, loosening of adhesive and deterioration.

SUMMARY OF TI-IE INVENTION A panel assembly adapted for use in door panels and the likecomprises a pair of longitudinal channels havinga plurality of flanges spaced from each other to define a track-for receiving a sheet of covermaterial. A plurality of crossmembers extend between thechannels, each of the crossmembers having a planar portion positioned to contact and be attachedto a face of the cover materialwhen the. cover material is received in the track. Positioning means is provided which coacts between the crossmembers and the longitudinal channels to position the channels in substantially parallel relation other and fastening means is provided to fasten the longitudinal channels and crossmembers together to form a rigid as sembly.

These and other objects, features and advantages of the present invention will become evident upon consideration of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1, assembled to form a two panel folding door construction;

FIG. 3 is a cross-sectioned view of a portion of a crossmember of the panel assembly taken along line 3-3 of FIG. 2;

FIG. 4 is a crosssectioned view of the longitudinal channel of the panel assembly taken along line 4-4 of FIG. 2;

FIG. 5 is a fragmentary plan view of a dimensionally adjustable panel assembly constructed in accordance with the principles of my invention;

FIG. 6 is a cross-sectioned elevation view of the panel assembly taken along line 6-6 of FIG. 5; and

FIG. 7 is a cross-sectioned elevation view of a double faced panel assembly constructed in accordance with the principles of my invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. l-4, a preferred embodiment of panel assembly is shown for use in a folding door construction such as a folding closet door. The assembly comprises a pair of Iongitudinal channels 10 and 12 having three integrally formed elongated flanges 14, Hand 16 extending axially along the length of the channels and in a lateral direction from the web 18 of each channel. Referring particularly to FIG. 4, flange 14 plication as willbe described in more detail later. The

shoulder 22 of flange 14 is spaced from flange 15 by an amount so as to form a track 25 which closely accommodates the edge thickness of a flat, substantially planar and aesthetically pleasing sheet of cover material 26 for the door panel. The cover sheetmay be formed of a variety of suitable materials such as plywood, Masonite, paperboard, hardboard,

veneered woods and mirrors, such mentioned materials not being deemed to be all inclusive.

A plurality of cross channels 28, 29 and 30 are provided, extending between the longitudinal channels 10 and 12. The

cross channels 28, 29 and 30 each comprise a substantially-U- shaped channel having a web 32 and a pair of flanges 34 extending substantially perpendicular to the web 32. The flange 16 of each of the longitudinal channels 10 and 12 includes a plurality of spaced elongated slots 36 and the web 32 of the cross channels carries a projecting elongated tongue 38 at each end which is adapted to be inserted into the slots 36. The tongue-and slot construction operates to accurately space the longitudinal channels 10 and 12 in spaced parallel relationship to each other during assembly and to substantially rigidify the assembly against twisting and loosening. After positioning of the channels by inserting the tongues 38 into the slots 36, a suitable means,'such as a rivet or sheet metal screw 40, is positioned in apertures 42 to firmly hold the cross channels 28, 29 and 30 and lon itudinal channels 10 and 12 in attached relationship to each other. The provision of the tongue and slot arrangement also minimizes the number of rivets or screws necessary to assemble the panel assembly, since the slot and tongue prevents twisting of the assembly.

When the cross channels 28, 29 and 30 have been attached to the longitudinal channels and 12, flanges 44, formed along the longitudinal distal edge of each of the flanges 34 of the cross channels, are arranged in a position substantially in the same plane as the flange of the longitudinal channels 10 and 12 and are in abutting relationship with the back face of the cover sheet 26. Each of the flanges also includes an axially extending ribbed passage 46 which strengthens the flanges and serves in the application of adhesive, a description of which follows.

When the cross channels 28, 29 and 30 have been attached to the longitudinal channels 10 and 12, a sheet of the desired cover material 26 is slideably inserted into the track formed between flanges 14 and 15. A suitable flowing adhesive 47, such as a vinyl adhesive, is then injected through apertures 48 and 49 formed, respectively, in the passage 24 and 46 of flanges l5 and 44, the adhesive proceeding at least partially along the length of the passage 24 and 46 and contacting the back face of the cover sheet material 26. The adhesive 47 bonds to cover sheet 26 at 50 and, after injection, the assembly is positioned such that the apertures 48 and 49 face downwardly to allow a small portion of the still fluid adhesive to flow by gravity back through the apertures in a reverse direction and harden to form a studhead 52. Thus, the cover sheet is firmly attached to the flanges l5 and 44 at a plurality of points and subsequent warping and deterioration is avoided and an extremely sturdy construction realized. In order to facilitate positioning of the discharge nozzle of the adhesive dispensing device, apertures 54 are provided in flange 16 in alignment with apertures 48.

To form a folding door arrangement, a plurality of hinges 56 are provided and the same rivet or screw 40 which attaches the cross channels 28, 29 and to the longitudinal channels 10 and 12 may be utilized to affix the hinges to two or more of the panel assemblies. Suitable hardware 58 may also be provided for adapting the folding door for sliding move-in a conventional slide track, the hardware. being attached to the upper and lower cross channels 28 and 30, as shown in FIG. 2.

Referring to FIG. 5, a construction is shown wherein the panel assembly is adjustable and may be selectively dimensioned at the place of use to conform to the dimensional needs of the user. Many of the components of the assembly are substantially similar in many respects to the assembly components previously described and this thus like reference numerals will be employed to designate substantially like components. In the adjustable assembly, the cross channel 60 comprises a pair of members 62 and 64 having webs 66 and 68 and flanges 70 and 72 forming a pair of substantially U-shaped channels 74 and 76, and flanges 78 and 80. The channel 76 of member 64 is slightly smaller than the channel 74 of member 62 and is adapted to be slideably inserted in the latter in a telescopic relationship to a plurality of selected depths. A plurality of apertures 82 are provided in the web 68 of member 64 and a single aperture 84 is provided in the web 66 of member 62. A sheet metal screw 86 is inserted through aperture 84 and a selected one of the apertures 82 to hold the telescoped members in their finally desired length relationship.

The height of the door may also be selected at the place of use. To enable such selective dimensioning, the longitudinal channels 10 and 12 include incremental notches 88 at their ends such that the longitudinal channels may be sawed before assembly to the length desired. The end slot 90 in flange 16 of the longitudinal channels is substantially elongated over the range that the channel is adapted to be adjusted, the slot or the remaining portion thereof after shortening of the channel receiving the tongue 38 of the cross channels as previously described. A plurality of apertures 92 are also provided over the range of adjustment of the longitudinal channels for receiving the sheet metal screw after the length of the longitudinal channel has been selected.

In each of the previously described assemblies, it is preferred that the edge 94 of the flanges 44 or 78 of the upper and lower cross channels coincide substantially with the ends of the longitudinal channels. When the edges of the flanges are so positioned, the flanges act to reinforce the top and bottom edges of the sheet cover material 26 preventing chipping and wear during use.

Referring to FIG. 7, an assembly is shown in which both faces are covered with cover sheet material. A first pair of flanges 96 and 97 and a second pair of flanges 98 and 99 are provided to fomi a first track 101 and a second track 102, respectively along the longitudinal edges of the web 104 of each of the longitudinal channels 106 and 107 to receive a pair of cover sheets 109 and 110. Each of the flanges 97 and 99 are somewhat wider than those previously described and a plurality of rigid cross straps 112 are provided extending between the flanges 97 and 99 of each of the longitudinal channels. The cross straps are positioned to engage the inside faces of each of the cover sheets 109 and 110 when the sheets have been inserted in the respective tracks 101 and 102. The cross straps 112 are attached at each of their ends to the flanges 97 and 99 by suitable fastening means, such as rivets 114. The cross straps act to position each of the longitudinal channels 106 and 107 in parallel spaced relationship to each other and reinforce the cover sheet material. Each of the straps 112 and the flanges 97 and 99 include an axially extending ribbed passage 116 and 117, respectively, having apertures 118 for the introduction of a suitable adhesive 120, as previously described.

It will readily be evident upon consideration of the foregoing detailed description, that the assembly of my invention makes possible the assembly of panels by the user, the necessity of assembly at the point of manufacture being obviated. Consequently, an assembly is provided in which the longitudinal channels and cross channels or straps only need be shipped to the retailer or user. Thus, the cost of shipping as well as the cost of manufacture is substantially reduced since the final assembly of the door panel may be accomplished in a geographical location where the sheet cover material is readily available. Also since the assembly is capable of final assembly by the ultimate user, the user may select and customize the door panel to satisfy his particular aesthetic desires, by choosing a cover sheet material of his liking. Moreover the assembly of my invention is extremely rigid and substantially reduces the possibility of warping of the sheet cover material and deterioration of same in use.

Although the assembly of my invention has been described in terms of a door panel construction, it will be readily apparent that the assembly may be employed in other types of panel arrangements and uses. It should also be understood the embodiments of the invention which have been described are merely illustrative of some of the applications of the principles of the invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention.

I claim:

1. An assembly for use in a door panel construction or the like comprising:

a pair of longitudinal channels each having a web and first and second flanges extending substantially perpendicular to said web, said first and second flanges being spaced from each other to define a track for slideably receiving a substantially planar sheet of material therein;

a plurality of crossmembers extending between said longitudinal channels, each of said crossmembers having a generally planar portion positioned substantially in the plane of the first flange of the longitudinal channels, the first flange of the longitudinal channels and the planar portion of the crossmembers being arranged to contact and be attached to a face of the sheet of material when the sheet of material is received in the track;

means coacting between said crossmembers and longitudinal channels for positioning said longitudinal channels in substantially parallel relation to each other and spaced flanges and crossmembers and said slot means being defined on the other of said third flanges and crossmembers.

- 3. The assembly of claim 2 wherein said slot means comprises an elongated slot which is normally substantially greater in length than said tongue means and said slot is defined on said third flange and said tongue means is carried on said crossmember. v

4. The assembly of claim 1 wherein at least one of said planar portions and first flanges define apertures for receiving fastening means to fasten a face of the sheet of material to same when said sheet of material is located in said track.

5. The assembly of claim 4 wherein at least one of said planar portions and first flanges include an elongated passage arranged to open along its length to said face of the sheet of material when the sheet of material is located in the track, said apertures communicating with said'passage for introducing an adhesive into said passage.

6, The assembly of claim 1 wherein said crossmembers comprise a first member having a web-and a pair of flanges defining a first generally U-shaped channel, a second member having a web and a pair of flanges defining a second generally U- shaped channel, said second U shaped channel being telescopically received in said first U-shaped channel, and fastening means for fastening said- U-shaped channels together to form a cross channel having a selected length.

7. The assembly of claim 6 wherein each of said longitudinal channels includes a third flange extending substantially perpendicular to said web of said longitudinal channels and spaced from said first and second flanges and said positioning means comprises an elongated tongue carried on said crossmembers and an elongated slot defined on said third flange and having a normally substantially greater length than said tongue, said tongue extending into said slot.

8. The assembly of claim 1 further including a second said rigid assembly and hinge means attaching one of said longitudinal channels of each assembly together, whereby said assemblies may be folded.

9. The assembly of claim 1 wherein said longitudinal channels include third and fourth flanges being spaced from each other to define a second track for slideably receiving a second substantially planar sheet of material in spaced parallel relationship to the first sheet of material, and said crossmembers extendbetween the first flanges and the third flanges, respectively, of each of said longitudinal channels.

10. A door panel assembly or the like comprising:

a pair of longitudinal channels each having a web and first and second flanges extending substantially perpendicular to said web, said first and second flanges being spaced from each other to define a track;

a substantially planar sheet of material slideably received in each of said tracks;

a plurality of crossmembers extending between said longitudinal channels, each of said crossmembers having a generally planar portion contacting a face of said sheet of material, said crossmembers including means positioning said longitudinal channels in substantially parallel relation to each other and spaced a predetermined distance from each other;

an elongated ribbed passage defined on at least one of said planar portions and first flanges opening along its length to said face of said sheet of material and having a plurality of apertures spaced along its len th; and adhesive means extending ongitu mally m at least a portion 

1. An assembly for use in a door panel construction or the like comprising: a pair of longitudinal channels each having a web and first and second flanges extending substantially perpendicular to said web, said first and second flanges being spaced from each other to define a track for slideably receiving a substantially planar sheet of material therein; a plurality of crossmembers extending between said longitudinal channels, each of said crossmembers having a generally planar portion positioned substantially in the plane of the first flange of the longitudinal channels, the first flange of the longitudinal channels and the planar portion of the crossmembers being arranged to contact and be attached to a face of the sheet of material when the sheet of material is received in the track; means coacting between said crossmembers and longitudinal channels for positioning said longitudinal channels in substantially parallel relation to each other and spaced a predetermined distance from each other, said positioning means comprising slot means and tongue means on at least some of said members and channels, said tongue means extending into spaced portions of said slot means; and fastening means fastening said longitudinal channels and crossmembers to form a rigid assembly.
 2. The assembly of claim 1 wherein each of said longitudinal channels includes a third flange extending substantially perpendicular to said web and spaced from said first and second flanges, said tongue means being carried on one of said third flanges and crossmembers and said slot means being defined on the other of said third flanges and crossmembers.
 3. The assembly of claim 2 wherein said slot means comprises an elongated slot which is normally substantially greater in length than said tongue means and said slot is defined on said third flange and said tongue means is carried on said crossmember.
 4. The assembly of claim 1 wherein at least one of said planar portions and first flanges define apertures for receiving fastening means to fasten a face of the sheet of material to same when said sheet of material is located in said track.
 5. The assembly of claim 4 wherein at least one of said planar portions and first flanges include an elongated passage arranged to open along its length to said face of the sheet of material when the sheet of material is located in the track, said apertures communicating with said passage for introducing an adhesive into said passage.
 6. The assembly of claim 1 wherein said crossmembers comprise a first member having a web and a pair of flanges defining a first generally U-shaped channel, a second member having a web and a pair of flanges defining a second generally U-shaped channel, said second U-shaped channel being telescopically received in said first U-shaped channel, and fastening means for fastening said U-shaped channels together to form a cross channel having a selected length.
 7. The assembly of claim 6 wherein each of said longitudinal channels includes a thiRd flange extending substantially perpendicular to said web of said longitudinal channels and spaced from said first and second flanges and said positioning means comprises an elongated tongue carried on said crossmembers and an elongated slot defined on said third flange and having a normally substantially greater length than said tongue, said tongue extending into said slot.
 8. The assembly of claim 1 further including a second said rigid assembly and hinge means attaching one of said longitudinal channels of each assembly together, whereby said assemblies may be folded.
 9. The assembly of claim 1 wherein said longitudinal channels include third and fourth flanges being spaced from each other to define a second track for slideably receiving a second substantially planar sheet of material in spaced parallel relationship to the first sheet of material, and said crossmembers extend between the first flanges and the third flanges, respectively, of each of said longitudinal channels.
 10. A door panel assembly or the like comprising: a pair of longitudinal channels each having a web and first and second flanges extending substantially perpendicular to said web, said first and second flanges being spaced from each other to define a track; a substantially planar sheet of material slideably received in each of said tracks; a plurality of crossmembers extending between said longitudinal channels, each of said crossmembers having a generally planar portion contacting a face of said sheet of material, said crossmembers including means positioning said longitudinal channels in substantially parallel relation to each other and spaced a predetermined distance from each other; an elongated ribbed passage defined on at least one of said planar portions and first flanges opening along its length to said face of said sheet of material and having a plurality of apertures spaced along its length; and adhesive means extending longitudinally in at least a portion of said passage bonded to the face of said sheet of material and also extending through said apertures, the latter extended portion forming a head larger in size than said apertures to firmly contain said one of said first flanges and said planar portions between the head and the portion of the adhesive means in said passage and firmly attach said sheet of material thereto. 